Spandrel construction

ABSTRACT

The invention provides spandrels comprising non-visionary masking material carried by insulating glass units, monolithic panes, and other substrates. In certain embodiments, there is provided a spandrel comprising at least one pane having first and second generally-opposed major surfaces at least one of which is a covered surface bearing a non-visionary covering comprising a plurality of strips of opacifier film. Further, certain embodiments provide a method of constructing a spandrel. The method comprises; providing a pane having first and second generally-opposed major surfaces; and applying a plurality of strips of opacifier film to one of the major surfaces of the pane to define a covered surface bearing a non-visionary covering.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation-in-part of U.S. patentapplication filed Aug. 28, 2001 and assigned Ser. No. 09/940,970, theentire disclosure of which is incorporated herein by reference. Inaddition, the present application claims priority to the U.S. patentapplication filed Feb. 12, 2002 and assigned Ser. No. 10/076,211, theentire disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to spandrels comprisingnon-visionary masking material carried by insulating glass units,monolithic panes, and other substrates. More particularly, thisinvention relates to spandrels carrying particularly advantageousconfigurations of non-visionary masking material.

BACKGROUND OF THE INVENTION

[0003] In most industrialized countries, windows touch people's liveseveryday. Wherever people work and live there are windows. Windows allowoccupants of a building to view the outside world while allowing sunlight to enter the interior of the building. Sunlight is a naturalantidepressant and helps the human body produce vitamin D. Thus, acertain amount of sunshine is essential to mental and physical wellbeing. Since windows deliver sunshine, they can be seen to contribute tothe mental and physical well being of the community.

[0004] Many skyscrapers and other buildings have exterior facades thatare defined largely by glass (e.g., curtainwalls). In such buildings,the glass facades commonly include both visionary and non-visionaryareas. Visionary areas are referred to as windows, while non-visionaryareas are referred to as spandrels. Spandrels are designed to visuallyconceal portions of a building that are preferably not visible from theexterior of the building (e.g., floor slabs, areas between floors,vertical spans between floors and ceilings or between successive viewingclosures, insulation, heating and air conditioning components, etc.).

[0005] Spandrels are commonly either monolithic or insulating glass.That is, a spandrel commonly includes either a single pane or amultiple-pane insulating glass unit (i.e., an IG unit). The pane or IGunit of a spandrel is rendered opaque, commonly by one of two basicmethods. The first method involves applying a ceramic frit onto a glasssurface and subsequently firing the pane in a tempering furnace to forma permanent bond between the frit and the pane. Ceramic frit is somewhatlimited in its applicability, though, since it may burn or otherwisedamage any underlying coating when fired. As a consequence, ceramic fritis typically only used on the uncoated surfaces of IG units because mostcoated glasses cannot withstand the temperatures required for firing thefrit. Thus, the versatility of ceramic frit is somewhat limited.

[0006] The second basic method of creating a spandrel involves applyingan opacifier film to a glass surface. The opacifier film, which iscommonly black or otherwise opaque, may be formed of plastic, vinyl,polyester, polyethylene, or the like. The film is typically applied tothe glass with a water or solvent based adhesive. When opacifier film isused in a monolithic spandrel, the film is typically applied over the #2surface of the glass, commonly over a reflective coating born directlyon the #2 surface. When opacifier film is used in an insulating glassspandrel, the film is commonly applied to the #2 surface, #3 surface, or#4 surface. The terms used to denote the particular surfaces of a paneor IG unit (e.g., “#1 surface”, “first surface”, “#2 surface”, etc.) aredefined below.

[0007] Opacifier film is conventionally applied in the form of a singlesheet sized to cover the whole of the pane surface that is to beopacified. Using one large sheet on each opacified surface, however, hasits limitations. For example, consider a sheet of opacifier film that isdiscarded after being inadvertently miscut (e.g., cut to dimensions notmatching the intended surface), mislaid (e.g., poorly applied to theintended surface), damaged, or otherwise rendered unusable. If thissheet has been sized to cover the whole opacified surface, then arelatively large amount of opacifier film will be discarded. This wastesan unnecessary amount of opacifier film, which then must be removed fromthe manufacturing facility and thrown out, recycled, or otherwisediscarded, thus increasing costs in multiple respects.

[0008] Further, applying large, single sheets of opacifier film isunnecessarily complicated for manufacturers who produce a variety ofspandrels of different sizes and shapes. For example, such manufacturerswould either have to stock film of different widths to accommodate panesof different size, or stock film of great enough width to accommodatetheir largest pane size and then, when smaller panes are to be covered,cut the width of each sheet to match the particular width of a givensmaller pane. The former alternative is less than ideal in that themanufacturer has to stock rolls of opacifier film of different widths(e.g., possibly one roll size per each pane size produced). The formeralternative also renders the film-application process undulycomplicated, particularly if the process is automated, in that itimposes an additional roll-selection/changing step on thefilm-application process. The latter alternative is less than ideal inthat it involves an additional width-cutting step, creates unnecessarywaste (i.e., the cut-away portions of film), and may require anadditional waste-removal step (e.g., removing the cut-away film from thepane and/or from the film-application station). Thus, it can beappreciated that the conventional methods of applying opacifier film,and the resulting spandrel constructions, are less than ideal.

SUMMARY OF THE INVENTION

[0009] Certain embodiments of the invention provide a spandrelcomprising at least one pane having first and second generally-opposedmajor surfaces at least one of which is a covered surface bearing anon-visionary covering comprising a plurality of strips of opacifierfilm.

[0010] Further, certain embodiments of the invention provide a method ofconstructing a spandrel. The method comprises: providing a pane havingfirst and second generally-opposed major surfaces; and applying aplurality of strips of opacifier film to one of the major surfaces ofthe pane to define a covered surface bearing a non-visionary covering.

DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a perspective view of a spandrel assembly in accordancewith certain embodiments of the present invention;

[0012]FIG. 2 is a cross-sectional side view of a spandrel in accordancewith certain embodiments of the invention;

[0013]FIG. 3 is a cross-sectional top view of a verticalspandrel-mounting construction in accordance with certain embodiments ofthe invention;

[0014]FIG. 4 is a cross-sectional perspective view of a spandrelassembly in accordance with certain embodiments of the invention;

[0015]FIG. 5A is a front view of a glazing having both a spandrel areaand a window area in accordance with certain embodiments of theinvention;

[0016]FIG. 5B is a cross-sectional side view of the glazing of FIG. 5Ataken along lines 5B; and

[0017]FIG. 6 is a flow chart illustrating an exemplary method inaccordance with certain embodiments of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0018] The following detailed description is to be read with referenceto the drawings, in which like elements in different drawings have beengiven like reference numerals. The drawings, which are not necessarilyto scale, depict selected embodiments and are not intended to limit thescope of the invention.

[0019] The invention provides a spandrel comprising at least one pane.As can be appreciated with reference to FIG. 1, the pane is typically agenerally flat, sheet-like substrate. Thus, the substrate typically hastwo generally-opposed major surfaces, which preferably are planar andsubstantially parallel to each other. In most cases, the substrate willbe a sheet of transparent material. For example, the substrate may be asheet of glass, clear plastic, or the like. One commonly-used type ofglass is soda-lime glass. Soda-lime glass is a preferred substrate. Ofcourse, other types of glass can be used as well, including thosegenerally referred to as alkali-lime-silicon dioxide glass, phosphateglass, and fused silicon dioxide. When the present spandrel comprisesone or more panes of glass, it will typically be preferred to employglass that is heat treated, heat strengthened, or tempered in order toreduce the opportunity for thermal breakage. In addition, heat treatedglass would be more suitable in meeting wind requirements. It will bewell within the purview of those skilled in the present art to selectappropriate substrate materials (e.g., heat-strengthened glass versusfully-tempered glass) for different spandrel applications.

[0020] Thus, the spandrel comprises a pane having first and secondgenerally-opposed major surfaces. A non-visionary covering (describedbelow) is disposed over one of the major surfaces of the pane (thismajor surface is referred to herein as the “covered surface”). Incertain embodiments (e.g., where the whole area of the pane is opaque),the non-visionary covering is disposed over substantially the entirearea of the covered surface. For example, the covered surface of thepane may have an uncovered peripheral apron (i.e., the non-visionarycovering may have a “cut-back”), but otherwise may be entirely coveredby the non-visionary covering. In one such embodiment, the non-visionarycovering is disposed over a central portion of the covered surface,which central portion spans at least about 75%, more preferably at leastabout 80%, and perhaps optimally at least about 85%, of the area of thecovered surface. In embodiments where the non-visionary covering has acut-back, sealant can be applied directly to the pane at its uncoveredperipheral apron. In other embodiments, the non-visionary covering doesnot have a cut-back, but rather is disposed over the entire area of thecovered surface. In such cases, sealant may be bonded directly to thenon-visionary covering. Further, the invention provides embodimentswherein there is provided a pane or IG unit having both a non-visionaryspandrel area and a visionary window area, as described with referenceto FIGS. 5A and 5B. Skilled artisans will appreciate that the opacifierstrip configurations of this invention can be used advantageously withany desired spandrel or spandrel area.

[0021] As noted above, the present spandrel may be monolithic or it maybe insulating glass. In embodiments where the spandrel is monolithic,the non-visionary covering is preferably carried on the #2 surface ofthe pane, optionally over a reflective coating 40 born directly on the#2 surface. In embodiments where the spandrel comprises an IG unit, thenon-visionary covering is preferably carried on the #2 surface, #3surface, or #4 surface of the IG unit. In such embodiments, the IG unitmay be provided with a reflective coating 40. This coating 40 wouldcommonly be born directly on the #2 surface. For example, the IG unitmay bear a reflective coating 40 on the #2 surface, while thenon-visionary covering 120 may be carried on the #3 or #4 surface. Inboth monolithic and insulating glass spandrel embodiments, anyconventional reflective coating for spandrels can be used. Coatings ofthis nature are well known in the art.

[0022] The terminology used to refer to particular major surfaces willnow be described. As is conventional in the art, the terms “firstsurface” and “#1 surface” refer to the major surface that is exposed to(i.e., communicates with) the outdoor environment. In FIGS. 2, 3, and 5,the outer surface 14 or 104 of the pane 2A or 102 is the so-called firstsurface. Moving from the #1 surface toward the interior of the building99, the next major surface is the “second” (or “#2”) surface. Withcontinued reference to FIGS. 2, 3, and 5, the inner surface 24 or 114 ofthe pane 2A or 102 is the so-called second surface. In the monolithicembodiment of FIG. 2, the #2 surface is exposed to a cavity 350 betweenthe spandrel and the building 99. In the insulating glass embodiment ofFIG. 5B, the #2 surface is exposed to the between-pane space 15 of theIG unit 36. In such an embodiment, the next major surface (moving fromthe #2 surface further toward the interior of the building) is the“third” (or “#3”) surface, followed by the “fourth” (or “#4”) surface.With reference to FIG. 5B, the inner surface 24′ of the pane 2B is theso-called third surface, and the outer surface 14′ of this pane 2B isthe so-called fourth surface.

[0023]FIG. 1 is a perspective view of a monolithic spandrel assembly 100in accordance with certain embodiments of the invention. This spandrelassembly 100 includes a single pane 102 having two generally-opposedmajor surfaces 104, 114. At least one of these major surfaces is acovered surface bearing a non-visionary covering. In the monolithicspandrel embodiments of this invention, the non-visionary covering 120is born on the pane surface 114 that, following mounting adjacent aconcealed portion of a building 99, will be the #2 surface of thespandrel. This is perhaps best appreciated with reference to FIG. 2,which illustrates a monolithic spandrel comprising a pane 102 mountedadjacent a concealed portion of a building 99. In this embodiment, itcan be appreciated that the non-visionary covering 120 is carried on thepane surface 114 that is oriented toward, and exposed to, the cavity 350between the spandrel and the concealed portion of the building 99. Theconcealed portion of the building may be a floor slab, an area betweenfloors, a vertical span between floors and ceilings or betweensuccessive viewing closures, insulation, a heating and air conditioningcomponent, or any other part of the building that is preferably notvisible from the exterior of the building.

[0024] With continued reference to FIG. 1, it can be appreciated thatthe non-visionary covering 120 comprises a plurality of strips ofopacifier film. As illustrated, the strips of opacifer film preferablyare disposed in a sequentially-overlapped fashion with each subsequentstrip overlapping a portion of a preceding strip. The non-visionarycovering 120 shown in FIG. 1 includes a first strip 130A and a secondstrip 130B that partially overlaps the first strip 130A. In thisembodiment, the non-visionary covering 120 also includes a third strip130C that partially overlaps the second strip 130B. Thus, one embodimentof the invention provides a non-visionary covering 120 comprising atleast three, and perhaps more preferably at least four, contiguousstrips of opacifier film applied in a sequentially-overlappedconfiguration. The non-visionary covering 120 may comprise any pluralnumber of strips without deviating from the scope of the invention.

[0025] In the embodiment of FIG. 1, the overlapped strips of opacifierfilm are applied in a particularly desirable configuration wherein thestrips are generally parallel to one another. That is, the pane 102 hasa plurality of elongated strips of opacifier film extendingsubstantially in parallel across the pane surface 114. Preferably, theoverlapped strips of opacifier film are applied in a configurationwherein all of the strips are precisely parallel to one another. It isalso preferable to apply all of the strips at precisely the same length.Thus, the strips can be applied in a configuration wherein they areprecisely parallel and have precisely the same length. Configurations ofthis nature are especially advantageous in cases where the pane 102 hasa square or rectangular shape. For example, a square or rectangularnon-visionary covering can be applied in this manner with a great dealof accuracy. In more detail, each peripheral edge (of the non-visionarycovering 120) that is defined by multiple strips (i.e., each compositeperipheral edge 121C) can be precisely aligned by applying theoverlapped strips in this manner. Preferably, the ends of the stripsthat define each composite peripheral edge 121C are precisely alignedwith one another, such that each composite peripheral edge 121C isuniformly parallel to, and uniformly equidistant from, the adjacent edgeof the pane. In most cases, it will be optimal to configure thenon-visionary covering 120 such that all of its peripheral edges 121(not just the composite peripheral edges 121C) are uniformly parallelto, and uniformly equidistant from, respective adjacent edges of thepane.

[0026] The overlapped strips of opacifier film can be configured toextend in any direction across the covered surface of the pane. In theembodiment of FIG. 1, the strips of opacifier film are applied such thattheir length (i.e., their major dimension) extends across the width(i.e., the minor dimension) of the pane surface, rather than across thelength (i.e., the major dimension) of this surface. It may bepreferable, though, to apply the strips of opacifier film across thelength of the pane surface.

[0027] Thus, the non-visionary covering 120 preferably comprises aplurality of strips of opacifier film applied in a sequentiallyoverlapping fashion. The amount by which adjacent strips overlap oneanother (i.e., the “overlap dimension”) can be varied as desired. Thisis perhaps best appreciated with reference to FIG. 1, wherein theoverlap dimension is denoted by the reference character “D”. The overlapdimension D is equal to the distance between two adjacent overlappededges 13, 16. The overlap dimension D is selected, in conjunction withthe number of strips, to yield a non-visionary covering 120 of thedesired size. An illustrative range for the overlap dimension D isbetween about {fraction (1/16)} inch and about 2 inches, or perhaps morepreferably between about ⅛ inch and about 1½ inches. However, theoverlap dimension can be varied as desired.

[0028] As noted above, the non-visionary covering 120 is provided with acut-back in certain embodiments, i.e., in structural glazingapplications. For example, the covered surface of the pane may have anuncovered apron (i.e., an uncovered surface area) between an outerperiphery 126 of the non-visionary covering 120 and an outer periphery128 of the pane 102. FIG. 1 depicts one embodiment of this nature,wherein the surface 114 of the pane 102 is entirely covered with theexception of an uncovered peripheral apron 124. In this embodiment, theuncovered apron 124 extends between a complete outer periphery 126 ofthe non-visionary covering 120 and a complete outer periphery 128 of thepane 102. That is, the entire periphery of the pane surface 114 isuncovered. A cut-back of this nature allows sealant 55 to be bondeddirectly to the pane, rather than to the opacifier film, as is perhapsbest appreciated with reference to FIG. 3.

[0029]FIG. 3 is a cross-sectional top view of a verticalspandrel-mounting construction in accordance with certain embodiments ofthe invention. FIG. 3 depicts two adjacent spandrels mounted to avertical structural framing member 95. Each spandrel comprises a pane102 joined at each vertical side region to a vertical structural framingmember 95 by a sealant joint 55 and a spacer 88. The sealant joint 55 istypically a structural silicone joint. In FIG. 3, a weather seal 56 isillustrated between the confronting edges of the panes. If provided, theweather seal 56 typically comprises silicone. The mounting constructionof FIG. 3 is merely one example of the manner in which the presentspandrel may be mounted to a building. Thus, it is to be appreciatedthat the present spandrel can be mounted to a building with any suitablemounting construction.

[0030] In embodiments like that shown in FIG. 3, the non-visionarycovering 120 is sized, shaped, and positioned on the pane surface suchthat, when the pane is secured to a confronting mounting surface 67, aperipheral edge 121 of the non-visionary covering 120 comes just to(e.g., abuts, but does not extend beneath) the inner edge of themounting surface 67. That is, the width W of the unmasked apron 124 isequal to the dimension OD by which the mounting surface 67 extends overthe surface 114 of the pane 102. In FIG. 3, the mounting surface 67 isdefined collectively by a sealant joint 55 and a spacer 88. In thisembodiment, a peripheral edge 121 of the non-visionary covering 120comes just to the inner edge of the sealant joint 55 (which iscontiguous to the spacer 88). Thus, the width W of the unmasked apron124 in this embodiment is equal to the dimension OD by which the sealantjoint 55 and the spacer 88 collectively extend over the surface 114 ofthe pane 102. While FIG. 3 depicts an embodiment where the mountingsurface 67 is defined by a sealant joint and a spacer, it will beappreciated that the spandrel can be secured to a variety of othermounting surfaces.

[0031] For example, FIG. 5B depicts an embodiment wherein the pane 2B issecured to a mounting surface 67 defined by a frame 68. In thisembodiment, the non-visionary covering 120 is sized, shaped, andpositioned on the pane surface 14′ such that, when the pane 2B issecured to the mounting surface 67, a peripheral edge 121 of thenon-visionary covering 120 comes just to the inner edge 69 of the frame68. Thus, the width W of the unmasked apron 124 in this embodiment isequal to the dimension OD by which the frame 68 extends over the surface14′ of the pane 2B.

[0032] In the embodiments of FIGS. 3 and 5B, the peripheral edge 121 ofthe non-visionary covering 120 does not extend beneath the mountingsurface 67. However, this is by no means a requirement. Rather, thenon-visionary covering 120 may extend beneath the mounting surface 67 toany desired extent. In fact, the non-visionary covering 120 may not haveany cut-back, and thus may be secured directly to a mounting surface 67,if so desired.

[0033]FIG. 4 is a perspective view of an insulating glass spandrelassembly 200 in accordance with certain embodiments of the invention.The illustrated spandrel assembly 200 comprises an IG unit 36 having twospaced-apart panes 2A, 2B joined at their peripheral confrontingsurfaces by a spacer 38. It is to be understood that the spandrelassembly 200 can comprise an IG unit of any type. In the insulatingglass spandrel embodiments of this invention, at least one of the panesof the IG unit bears a non-visionary covering 120. For example, the IGunit 36 shown in FIG. 4 has a non-visionary covering 120 on the outersurface 14′ of the pane 2B. Preferably, the non-visionary covering 120is carried on the #2 surface, #3 surface, or #4 surface of the IG unit36. For example, FIG. 5B depicts an embodiment wherein the non-visionarycovering 120 is carried on the #4 surface. The IG unit 36 is preferablyprovided with a reflective coating 40, as described above, which willcommonly be born on the #2 surface of the IG unit.

[0034] In the present insulating glass spandrel embodiments, thenon-visionary covering 120 comprises a plurality of strips of opacifierfilm. These strips of opacifier film are preferably disposed in asequentially-overlapped configuration with each subsequent stripoverlapping a portion of a preceding strip. This preferred stripconfiguration is thoroughly described above. Further, the non-visionarycovering 120 may be provided with a cut-back (i.e., the non-visionarycovering 120 may have an uncovered peripheral apron 124), as has alsobeen described.

[0035]FIGS. 5A and 5B depict an alternate embodiment of the inventionwherein there is provided an IG unit 36 having both a non-visionaryspandrel area 48 and a visionary window area 46. In this embodiment, thespandrel area 48 conceals a structural member 78 and other parts 75 ofthe building 99, while the window area 46 facilitates viewing frominside, and light passage into, the building 99. The spandrel area 48 isdefined by a non-visionary covering 120, which in FIGS. 5A and 5B iscarried on the lower portion of the IG unit 36. Of course, thenon-visionary covering 120 can be located on different portions of theIG unit 36 (e.g., on an upper or middle portion, rather than the lowerportion), depending on the position of the building structure to beconcealed. In FIGS. 5A and 5B, the non-visionary covering 120 is carriedon the #4 surface of the IG unit 36, although this covering 120 canalternatively be carried on the #2 or #3 surface. Further, the IG unit36 in this embodiment can be replaced with a monolithic pane having bothspandrel and window areas.

[0036] The non-visionary covering 120 in the embodiment of FIGS. 5A and5B comprises a plurality of strips of opacifier film. Preferably, thesestrips are disposed in a sequentially-overlapped fashion, as has beendescribed. In FIG. 5B, the peripheral edge 121 of the non-visionarycovering 120 has a cut-back. However, this is by no means required. Forexample, the non-visionary covering 120 in this embodiment canalternatively extend all the way to the edge LE of the pane 2B.

[0037] The non-visionary covering 120 can comprise any desired type ofopacifer film. A variety of opacifer films are known in the art, and theinvention is not limited to any particular type of opacifier film. Whilethe opacifier film will typically be opaque, translucent films may beused in some cases. In certain embodiments, the opacifier film comprisesa film material selected from the group consisting of vinyl, polyester,polyethylene, or the like. The opacifier film will commonly be a blackplastic film. Preferably, the opacifier film is secured to the pane witha water or solvent based adhesive. In one particular embodiment, theopacifier film comprises polyester (e.g., Mylar) secured to the panewith a solvent-based adhesive. U.S. Pat. No. 4,610,115, the entiredisclosure of which is incorporated herein by reference, describesopacifier films and adhesives that are suitable for use in the presentinvention.

[0038] The invention provides simplified processes for applyingopacifier film to panes of varying size. For example, a supply (e.g., aroll) of opacifier film can be selected such that the width of theopacifier film corresponds to a known minimum pane size. In oneembodiment, there is provided a roll of opacifier film having a widththat corresponds to (e.g., is equal to or slightly less than) the widthof a known minimum pane size. When it is desired to apply the film to apane of the known minimum size, the whole non-visionary covering 120 canbe formed by a single sheet of the opacifier film. On the other hand,when it is desired to apply the film to a larger pane, the non-visionarycovering 120 can be formed by applying multiple sheets of the opacifierfilm in the overlapping fashion described herein. The number of sheetsapplied, and the overlap dimension D of the sheets, is selected toachieve the desired pane coverage. Whether one or multiple sheets ofopacifier film are applied, the length of each sheet is preferablyselected to correspond to (e.g., to be equal to or slightly less than)the length of the pane.

[0039] Thus, it can be appreciated that a supply of opacifier film canbe conveniently used to opacify panes of many different sizes. Forexample, the present method avoids the need to stock rolls of opacifierfilm of different widths to accommodate panes of different size. Infact, it is only necessary to stock rolls of opacifier film having asingle width corresponding to a known minimum pane size. Moreover, inembodiments where an uncovered apron is left on the pane, the opacifierfilm can be applied without having to cut or otherwise affirmativelyremove marginal portions of the non-visionary covering. This affordssignificant efficiency in terms of time, labor, and money. It alsoprevents any damage that might otherwise be done to the pane duringremoval (e.g., cutting) of marginal portions of the opacifier film. Thismay be particularly advantageous in cases where the covered surfacebears a reflective coating, which may be vulnerable to abrasion bycutting wheels and the like.

[0040]FIG. 6 is a flow chart illustrating an exemplary method of theinvention. The method of FIG. 6 includes a step of providing a spandrelassembly (e.g., a pane or IG unit) to be opacified. For example, thisstep may comprise providing a pane (which may be monolithic or part ofan IG unit) having two generally-opposed major surfaces. The method ofFIG. 6 includes the step of providing a desired width of the pane areato be covered to a coverage calculator. For example, a pane or IG unitmay be moved into a film-application station. In the film-applicationstation, a total width of the pane or IG unit may be detected or inputby an operator, and this total width may be used to determine thedesired width of the pane area to be covered. For example, a controllerassociated with the film-application station may utilize this totalwidth in determining the width of the desired film coverage area.

[0041] The method of FIG. 6 also includes the step of providingopacifier film having a width. In a preferred method, the width of theopacifier film is selected to correspond to the width of the desiredfilm coverage area for a small pane or IG unit. In this preferredmethod, a small pane or IG unit can be opacified by applying a singlestrip of opacifier film to a surface of the pane or IG unit. Largerpanes and IG units can be opacified by applying multiple strips ofopacifier film in a sequentially overlapping fashion until the desiredcoverage area is achieved.

[0042] The method of FIG. 6 also includes the step of determining anoptimal number of strips. As described above, for a small pane or IGunit, the optimal number of strips may be one. For other panes and IGunits, multiple strips may be desired. The method of FIG. 6 alsoincludes the step of calculating an overlap dimension D. The width ofthe opacifier film and the optimal number of strips can be used tocalculate a desired overlap dimension D.

[0043] The method of FIG. 6 also includes the step of applying theoptimal number of strips. For example, the optimal number of strips ofopacifier film may be applied to a major surface of a pane or IG unit.In one method, the strips are applied in a sequential fashion with eachsubsequent strip partially overlapping the preceding strip by thecalculated overlap dimension D.

[0044] The present invention is concerned with the configuration ofopacifier film on a substrate in a way that is new in the present art,hence producing a spandrel that is also new in this art. The presentmethods of constructing a spandrel involve applying a plurality ofopacifier strips over a substrate, preferably in asequentially-overlapped fashion, such that a lateral edge portion (i.e.,a side portion) of each strip is covered by, or covers, a lateral edgeportion of another strip. While this technique leaves two overlappedlayers of opacifier film at each overlap area, the opacifier film ispreferably opaque such that the overlapped areas are not more visiblethan the non-overlapped areas.

[0045] In certain preferred embodiments of the invention, the overlappedopacifier strips that are utilized in constructing the spandrelgenerally have the same width (e.g., have substantially equal widths).For example, the width of each individual strip may not vary (i.e., maybe uniform) from one strip to the next (e.g., all of the strips of thespandrel may have the same, or substantially the same, width). Inembodiments of the invention in which the widths of different strips dovary from one strip to the next, it will generally be preferred that noone strip has a width (the term width is used here to refer to thedistance between the lateral edges of an opacifier strip) that is morethan twice as wide as another strip of the same spandrel. Preferably, noone strip will have a width that varies by more than 50% from any otherstrip of the same spandrel. More preferably, no one strip will have awidth that varies by more than 20% from any other strip of the samespandrel. In certain particularly preferred embodiments, the spandrelcomprises a plurality of overlapped strips of opacifier film, all ofwhich have the same (or substantially the same) width.

[0046] In selected embodiments of the invention, the assembled spandreldoes not have any portion where more than two opacifier strip plies areoverlapped (i.e., no portion of the spandrel has a thickness that isformed by more than two plies of opacifier film). This can beappreciated with reference to the embodiment in FIG. 1, which shows anassembled spandrel. At every junction between overlapping strips ofopacifier film, e.g., 130A and 130B, the overlapped portion is no morethan two plies thick, where one of the overlapping edges is placed ontop of the other. If insulation is used in an area next to a spandrel,it will commonly be desirable to keep the insulation a certain minimumdistance from the opacifier film to prevent the film from experiencingexcessively high temperatures. By limiting the number of plies at eachoverlapped portion on a spandrel to no more than two, there is lesspotential for exposing the overlapped strips to excessively hightemperatures. Moreover, the appearance of the spandrel could be lessuniform and undesirably noticeable at overlapped regions if more thantwo plies were overlapped at these regions.

[0047] In certain embodiments of the invention, whether a spandrel isutilized with an IG unit or a monolithic pane, the glazing surface thatcaries the opacifier film is oriented towards an enclosed (or “encased”)environment, such that this surface is exposed to a protectedenvironment (i.e., not an outdoor environment). For example, in aninsulating-glass spandrel, the opacifier film, if mounted on the #2, #3,or #4 surfaces as previously described, will be oriented toward either apane of glass or a building interior, and thus, will either be exposedto the between-pane space of the IG unit or the protected atmospherebetween the building and the spandrel. In regards to a monolithicspandrel, which only has a single pane, the spandrel, if mounted on the#2 surface as previously described, will likewise be oriented toward abuilding interior, and thus, be exposed to the protected atmospherebetween the building and the spandrel. Thus, in both IG and monolithicapplications, the spandrel is constructed with the opacifier stripsbeing applied to a surface that is protected against (i.e., concealedfrom) exposure to environmental elements, such as periodic contact withrain and other inclement weather, even though in certain embodiments,the opacifier strips are formed of a material that is not permeable(e.g., non-porous) to water.

[0048] In certain embodiments of the invention, the overlapped opacifierstrips of an assembled spandrel generally have the same thickness (theterm thickness is used here to refer to the distance between the top andbottom major surfaces of an opacifier strip, where the thickness is thesmallest dimension of a strip). Preferably, the thickness of eachindividual strip does not vary substantially from one strip to the next.This can help to establish a highly uniform, opaque appearance. Eachstrip will commonly be at least {fraction (1/64)}″ thick. However, thethickness of each opacifier strip may vary from spandrel to spandrel;for example, film thicknesses may range between about {fraction(1/256)}″ and about ¼″. Thus, while the thickness encountered indiffering spandrels may vary, the thickness of the opacifier stripsutilized on any particular spandrel preferably does not varysubstantially. In certain embodiments, the thickness of the opacifierfilm forming to the spandrel is less than about ¼″, preferably less thanabout ⅛″, and perhaps optimally less than about {fraction (1/16)}″.Preferably, though, the opacifier film forming the present spandrel isthick enough to be self-supporting (e.g., well above 10,000 angstroms,preferably above 50,000 angstroms, more preferably above 10 microns, andperhaps optimally above 100 microns).

[0049] In certain preferred embodiments of the invention, the overlappedopacifier strips are held down (i.e., secured to the pane) exclusivelyby adhesive or static cling. In these embodiments, no other attachmentdevice is utilized. For example, no nails, tacks, anchors, or otherfasteners are used. As indicated previously, the strips are typicallyapplied to the pane with a water or solvent based adhesive. Otherembodiments utilize other adhering mechanisms, e.g., cling wrap, staticwrap, tacking, or a combination of these mechanisms. Further, theoverlapped opacifier strips preferably are adhered permanently to thewindow. In other words, the strips are adapted for permanent attachmentto the pane, and ultimately are permanently adhered to the pane (e.g.,such that trying to pull the strips off the pane results in tearing ofthe strips). Referencing U.S. Pat. No. 6,489,024, the entire teachingsof which are incorporated herein by reference, the degree to which anadhesive may be removed can be evaluated on a scale from 0-10. A scoreof 0 indicates that the adhesive was readily transferred and showedlittle anchorage, scores of 5-7 indicate some anchorage, and a score of10 indicates little or no transfer of adhesive and significantanchorage, even under stress. Using this scale in regards to theadhesive used in this invention on the opacifier strips in fabricating aspandrel, it should be understood that the adhesive preferably exhibitsan “adhesivity score” ranging from 7 to 10, more preferably at least 8or 9, and perhaps optimally 10, indicating significant anchorage evenunder stress. Thus, while there is always some potential to remove theopacifier strips from the window even after the spandrel is assembled,the opacifier film preferably is adhered permanently to the pane, aswill be well understood by skilled artisans. Thus, the attempted removalof opacifier strips should preferably result in the opacifier stripsbeing ripped, as a result of the permanent manner in which they areadhered to the pane.

[0050] In selected embodiments of the invention, the whole pane area isopacified and thus, the whole pane has an opaque appearance. In otherwords, the pane has no vision area, but rather is entirely opacified bythe overlapped strips. As such, a building portion can be readilyconcealed entirely simply by placing a spandrel in front of thatbuilding portion. In turn, the spandrel would have no frontal visual orviewing area through which a passerby could see with the naked eye.Further, the spandrel of the invention preferably has novisibly-perceptible variance in terms of color (including lightness,hue, and chroma). Preferably, all of the opacifier strips have auniformly opaque appearance (and the strips preferably have no gapstherebetween and holes or other openings therein). The entire area ofeach opacifier strip on the spandrel may be opaque, such that the entirearea of the pane/spandrel is opacified. Thus, the appearance of thewhole spandrel area may have substantially uniform lightness, hue, andchroma. In light of the foregoing, the spandrel preferably comprises aplurality of overlapping opaque strips that are applied to the panesurface such that little if any visible radiation (i.e., “light”) passesthrough the spandrel. That is, substantially the entire area of a majorsurface of a pane is preferably covered by the overlapped strips ofopacifier film such that the spandrel as a whole allows substantially novisible radiation to pass through the spandrel. The material from whichthe opacifier film is formed preferably has a low transmission ofvisible radiation (i.e., no or substantially no transmission), and inturn, since the strips are overlapped and preferably cover substantiallythe entire pane, the spandrel as a whole allows little if anytransmission of visible radiation. The opacifier film is preferablyformed of material that (at one ply thickness) has an overalltransmission of visible radiation of less than 20%, more preferably lessthan 10%, and perhaps optimally 5% or less (e.g., about 0-2%).Preferably, all of the overlapped strips of opacifier film are applied(i.e., positioned) so as to form a single contiguous opacified area,which opacified area preferably covers substantially the entire visionarea of a pane so substantially no visible radiation is able to passbetween any of the strips. For example, the overlapped strips ofopacifier film are preferably arranged on the pane such that there areno gaps between adjacent strips.

[0051] In certain preferred embodiments of the invention, a majority ofthe opacifier strips of a spandrel are laid out in a parallel (or atleast substantially parallel) orientation to one another as the spandrelis assembled. For example, all of the opacifier strips of such aspandrel may be parallel to one another. Certain particularly preferredembodiments of the invention provide a spandrel comprising a pluralityof opacifier strips together forming an opacified pane area where all(or all but a few, e.g., all but 3-7) of the overlapped strips aregenerally parallel to one another. In certain embodiments, the spandrelcomprises at least one pane (which may be transparent prior to theapplication of the strips of opacifier film), wherein the entire area(or at least a major portion thereof, or substantially the entire area)of at least one major surface of the pane is covered by a plurality ofoverlapped strips (which preferably are generally parallel to oneanother) of opacifier film, wherein the pane is so covered by at leasttwo but no more than ten such strips, preferably between two and eightstrips, more preferably between three and six strips.

[0052] Several forms of invention have been shown and described, andother forms will now be apparent to those skilled in the art. It will beunderstood that the embodiments shown in the drawings and describedabove are merely for illustrative purposes, and are not intended tolimit the scope of invention.

What is claimed is:
 1. A spandrel comprising at least one pane havingfirst and second generally-opposed major surfaces at least one of whichis a covered surface bearing a non-visionary covering comprising aplurality of strips of opacifier film.
 2. The spandrel of claim 1wherein the pane is mounted adjacent a concealed portion of a building.3. The spandrel of claim 1 wherein the strips of opacifier film aredisposed in a sequentially-overlapped fashion with each subsequent stripoverlapping a portion of a preceding strip.
 4. The spandrel of claim 3wherein the strips of opacifier film extend substantially in parallelacross the covered surface of the pane.
 5. The spandrel of claim 1wherein the non-visionary covering is disposed over the entire coveredsurface of the pane.
 6. The spandrel of claim 1 wherein the coveredsurface of the pane has an uncovered apron between an outer periphery ofsaid non-visionary covering and an outer periphery of the pane.
 7. Thespandrel of claim 1 wherein the opacifier film is opaque.
 8. Thespandrel of claim 1 wherein the opacifier film comprises a film materialselected from the group consisting of vinyl, polyester, andpolyethylene.
 9. The spandrel of claim 1 wherein the opacifier film is ablack plastic film.
 10. The spandrel of claim 1 wherein the opacifierfilm is secured adhesively to the covered surface of the pane.
 11. Thespandrel of claim 1 wherein the opacifier film is polyester and issecured to the covered surface of the pane with a solvent-basedadhesive.
 12. The spandrel of claim 1 wherein the spandrel ismonolithic.
 13. The spandrel of claim I wherein the spandrel comprises amultiple-pane insulating glass unit of which said pane is part.
 14. Amethod of constructing a spandrel, the method comprising: providing apane having first and second generally-opposed major surfaces; andapplying a plurality of strips of opacifier film to one of the majorsurfaces of the pane to define a covered surface bearing a non-visionarycovering.
 15. The method of claim 14 further comprising mounting thespandrel adjacent a concealed portion of a building.
 16. The method ofclaim 14 wherein the strips of opacifier film are applied in asequentially-overlapped fashion with each subsequent strip overlapping aportion of a preceding strip.
 17. The method of claim 16 wherein thestrips of opacifier film are applied so as to extend substantially inparallel across the covered surface of the pane.
 18. The method of claim14 wherein the strips of opacifier film are applied so as to cover theentire covered surface of the pane.
 19. The method of claim 14 whereinthe strips of opacifier film are applied so as to leave the coveredsurface of the pane with an uncovered apron between an outer peripheryof the non-visionary covering and an outer periphery of the pane. 20.The method of claim 14 wherein the strips of opacifier film are appliedby securing them adhesively to the covered surface of the pane.